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  • 1. Technical Summary Siemens TIA Project: Leeuwkuil Mill, Mittal, Vereeniging 2005-2007
  • 2. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Background
    • Mill rolls special products
    • 12 Stands
    • Plant is a “hybrid” – analog/S5 PLC control:
      • Loop control – analog control
      • Shear length cutting – PLC control
    • Problems with spares
  • 3. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Requirements
    • Upgrade two existing S5 PLC’s to S7
    • Replace drives with microprocessor-based drives (Siemens SIMOREG)
    • Do away with analog control – new PLC functionality
    • Configure mill stored setup (“recipe-based”)
    • Replace operator desk
    • Put in a SCADA (WinCC) and operator panels
  • 4. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Phase 1
    • Phase 1 – commissioning Dec 2005/ Jan 2006
    • Replace drives with microprocessor-based drives (Siemens SIMOREG)
    • Add Mill PLC (S7) to work in conjunction with existing S5 PLC’s (hardwired communication interface)
    • Add SCADA and Multi Panel
    • Remove old cables
  • 5. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Phase 2
    • Phase 2 – commissioning Dec 2006/ Jan 2007
    • Add Shear PLC (S7)
    • Remove S5 PLC’s
    • Tune loop controllers without metal in mill (simulated)
    • Commission 3 flying shears
    • Commission length cutting
    • Update WinCC with setup features
  • 6. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Who/What/Why TIA…?
    • Totally Integrated Automation
    • Central Engineering from Simatic Manager of:
      • Drives – Drives ES Basic
      • SCADA – WinCC
      • Panels – WinCC Flexible
      • PLC’s
  • 7. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Central Engineering PLC Drives SCADA/ WinCC Panels
  • 8. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Easy Access to Drive Trace
  • 9. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Mill Setup (WinCC User Archives)
  • 10. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Drive Diagnostics/PLC SCL Decoding
  • 11. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Profibus Diagnostics
  • 12. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Value…?
    • Totally Integrated Automation
    • Controller tuning for loopers without metal in mill (prevent cobbles)
    • Diagnostics
      • Profibus N/W
      • Drives
    • Easy interfacing with S5 ET200U modules – Profibus feature
    • WinCC uses Web Client functionality – any machine on the network can access SCADA without extra software/licenses